ahsan choudhuri, ph.d....ahsan choudhuri, ph.d. professor and chair, department of mechanical...
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Ahsan Choudhuri, Ph.D.Professor and Chair, Department of Mechanical EngineeringMr. and Mrs. MacInstosh Murchison Chair II Professor in EngineeringDirector, NASA MIRO Center for Space Exploration & Technology ResearchUniversity of Texas at El Paso
Ryan Wicker, Ph.D.Professor, Department of Mechanical EngineeringMr. and Mrs. MacIntosh Murchison Distinguished Chair I Professor in Engineering Director, W. M. Keck Center for 3D Innovation The University of Texas at El Paso
2015 HBCU/UCR Joint Kickoff MeetingCrosscutting Research Technology ProgramNational Energy Technology Laboratory Department of Energy
27-28 October, 2015
Morgantown, WV
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Project Title: METAL THREE DIMENSIONAL (3D) PRINTING OF LOW-NITROUS OXIDE (NOX) FUEL INJECTORS WITH INTEGRATED TEMPERATURE SENSORS
Award No: DE-FE0026330 Investigators: Dr. Ahsan Choudhuri, Email: [email protected], Phone: 915-747-6905
Dr. Ryan Wicker, Email: [email protected] ,Phone: 915-747-7443 DOE Project Manager: Maria Reidpath, Email: [email protected], Phone: 304-285-4140 UTEP Business Contact: Irene Holguin, Email: [email protected], Phone: 915-747-5680 Period pf Performance: 10/01/2015-09/30/2018 Project Amount: $250,000 Research Team: Jorge Mireles and Jaime Torres UTEP Research Centers: W. M. Keck Center for 3D Innovation
NASA MIRO Center for Space Exploration and Technology Research
Project Information Objectives Background Technical Methods
Task Descriptions
Timeline Milestone Log Decision Points
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Objective 1: Development of design methodologies for Low-NOx fuel injectors with embedded temperature capabilities for Electron Beam Melting (EBM) based 3D Manufacturing.
Design for Additive Manufacturing: Component Design Features; Geometric Tolerance and Dimensioning
Design Features; Process Parameters and Part Quality
Objective 2: Development of optimum EBM process parameters and powder removal techniques to remove sintered powder from internal cavities and channels of Low-NOx fuel injectors with embedded temperature sensors.
Dry ice blasting, ceramic blasting, water jetting, chemical etching, ultrasonics (patented technology by UTEP – U.S. Patent No. 8,828,311 B2), and megasonic baths
Objective 3: Testing of the EBM fabricated Low-NOx fuel injector with integrated temperature measurement capabilities in a High Pressure Laboratory Turbine Combustor
Functionality and operability in a realistic environment (combustor pressure up to 1.2 MPa (~175 psi) using natural gas)
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Additive manufacturing is a process of creating parts directly from a computer model in a
layer-by-layer fashion
Seven classes of technologies
Material Extrusion
Material Jetting
Binder Jetting
Directed energy deposition
Vat photopolymerization
Sheet lamination
Powder bed fusion
Scan direction
Melted Particles
High-energy beam
Melting
Deposited powder
Un-melted powder
A2
Two Build Tanks200 x 200 x 350mm(7.8 x 7.8 x 13.75 in)
Ø = 300mm, h = 200mm(Ø = 11.81, h = 7.8 in.)
S12(modified for high temperatures)
One Build Tank200 x 200 x 180mm(7.8 x 7.8 x 7.0 in.)
Heat Shield
Build Table
Electron Gun
Powder Distributor
Powder Container
Optics
Filament
Arcam Released Materials Titanium Ti-6Al-4V
Titanium Ti-6Al-4V ELI
Titanium Grade 2
Cobalt-Chrome, ASTM F75
Research Materials Ti-6Al-4V
TiAl
CoCrMo
Rene alloys
Inconel 625
Inconel 718
Copper
Niobium
Iron based alloys
Other proprietary alloys
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Sensors can be embedded (without post-production component modifications) in EBM-fabricated components through two distinct processes:
Stop and Go of the fabrication process which allows sensor placement within a cavity during fabrication where the process is allowed to continue upon sensor placement
Post-integration of sensors in customized compartments selectively built within the part.
The Stop and Go process requires an extremely accurate re-alignment of the powder-bed during the restart process.
Metallization and shorting of sensors due to a considerable high temperature of the EBM process creates significant fabrication challenges and limit the types of sensors that can be embedded.
The Post-Integration of sensors is a practical alternative for components that can be effectively designed and fabricated with pre-built complex sensor compartments without the need for post-production component modifications.
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Embedded sensor
Sensor lead
Conductive material
Nonconductive material
Nonconductive material
Piezoceramic sensor
Partial part with pocket (Ti-6Al-4V)
Partial part with embedded sensor
(PZT/LiNbO3)
Smart part with embedded sensor
Cross section of smart part
Metallic components with embedded piezoceramic sensor for high efficiency energy system
Fabrication of complex structures
Real time performance feedback from desired location
Structural health monitoring
Pressure tube demonstration
Embedded Piezoceramic sensor
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EBM Fabricated Pintle-Injector for a 9 KN LO2/Methane Rocket Engine
LOX
LCH4
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Certain challenges are foreseen when creating internal cavities/channels within AM parts fabricated using powder bed fusion AM technologies such as electron beam melting
Geometric Tolerance and Dimensioning of internal cavities and channels
Removal of powder from internal channels/cavities as the powder to be removed has been lightly sintered during the fabrication process
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Test Component: Low-NOx
fuel injector with integrated temperature sensors (derived from the Solar Turbine low-NOx
fuel injector for natural gas )
Ceramic Insulated High Temperature Thermocouple: OMEGA® Nextel/XC-14-J-12
Inconel 718 and Inconel 625
3.2 to 3.8 mm diameter slender circular channels
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Objective 1: Development of design methodologies of Low-NOx fuel injectors with embedded temperature capabilities for EBM based 3D Manufacturing.
Task 1.1: Fabrication of test part for technology evaluation
parts will be fabricated (Inconel 718, Inconel 625, and/or Titanium alloys) to assess the dimensional accuracy of EBM-fabricated parts
various geometric shapes and features that can be potentially implemented in fuel injectors.
Letter Feature Factor To be Tested
A Square base
Dimensional accuracy
B (+) Lateral ridges
C (-) Lateral ridges
D (+) Descending cylinders
E (-) Descending cylinders
F (+) Staircase
G (-) Staircase
H (+) Cylinders
I (-) Cylinders
J Ramps Surface Roughness
K Rectangular prisms Linear displacement
error
L Tensile Bar Ultimate tensile strength
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Task 1.2: Evaluation of test parts
Dimensional accuracy
OGP Smartscope Flash 250
Mitutoyo SJ-201P surface roughness tester
Mechanical testing will be completed using the specification of the E8/E8M ASTM standard
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Task 1.3: Design for AM of Low-NOx fuel injector
Develop designs to fabricate the complete injector (using Inconel 718, Inconel 625, and Titanium alloys) in a single EBM build run.
The task will run in parallel to the powder removal tasks (Objective 2)
Final design will be created upon determining the appropriate powder removal strategies
Task 1.4: Designs for sensor integration as an assembly process
Cavities for placement of sensors
Implementation of fasteners or caps
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Objective 3: Testing of the EBM fabricated Low-NOx fuel injector with integrated temperature measurement capabilities in a High Pressure Laboratory Turbine Combustor
Task 2.1: Powder removal for internal channels
methods for powder removal to be explored include, but are not limited to, dry ice blasting, ceramic blasting, water jetting, chemical etching, ultrasonics, and megasonic baths
3 parts of each sized cavity will be fabricated and tested with each method
Task 2.2: Powder removal for internal cavities
To determine the appropriate number of outlets and outlet size that allow improved powder removal
Task 2.3: Process parameter modifications for improved optimal powder sintering
• To change the heat input to the sintered powder which consists of changing parameters such as beam speed, beam power, and beam focus.
• An improved parameter set would allow for the powder bed to become more or less sintered and easier to remove via the powder removal techniques
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Objective 3: Testing of the EBM fabricated Low-NOx fuel injector with integrated temperature measurement capabilities in a High Pressure Laboratory Turbine Combustor
Task 3.1: Functionality Assessments of the injector in a High Pressure Combustion Environment
Functionality of the injector with integrated temperature sensors will be evaluated using a Dynalene™ cooled high-pressure turbine combustor
AM fabricated injectors will be tested at a combustion pressure of 1.2 MPa (~175 psi) using natural gas (CH4)
The functionality and durability of the embedded sensors will evaluated during the test runs.
The post-run analyses of mechanical properties such as hardness and the tensile and compressive moduli of injector test articles will be measured to understand the stability and tolerance of AM fabricated components under extreme thermo-chemical conditions.
High Pressure Turbine Combustor
EBM-fabricated parts of various geometric shapes and features will be tested for dimensional accuracy, surface roughness and linear displacement.
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Test part and its design features
Dimensional Accuracy- utilizing the OGP Smartscope Flash 250 to measure the various geometric shapes and features.
Surface roughness- using a Mitutoyo SJ-201P surface roughness tester.
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Additional pieces will be fabricated with spiral internal channels of diameters 2mm,4mm,8mm and 10mm to test powder removal techniques
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10mm4mm 8mm 2mm
Powder bed fusion allows the creation of complex structures; however, structures that reside powder within internal features needs to be removed
A key topic in this research is to explore powder removal methods to enable access to internal cavities
Initial powder removal method to be explored will be the use of ultrasonic energy
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Document part weight versus
CAD comparison
Evaluate entrapped
powder locations
Apply ultrasonic energy and
recycle powder
Patented by UTEP for powder removal under U.S. Patent No. US 8,828,311 B2 Has been proven to remove powder from a variety of channel sizes without the need of fluids
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Mile-
stone
Title Description Success Metrics Reporting Qtr. Date Complete
Budget Period 1
M1 Updated Project
Management Plan
Complete plans for Facility,
Resources, Quality, Safety,
Documentation Management,
etc.
Predecessor of all
following tasks
Report Plan
delivered to DOE
PM
Q1-
Y1
TBD TBD
M2 Kickoff Meeting Review of objectives, technical
and managerial approach and
other facets of project
Predecessor for tasks Presentation
delivered to DOE
PM
Q1-
Y1
TBD TBD
M3 Development design
metrics for EBM-
fabricated parts
Design criteria and limitations for
low-NOx fuel injectors fabricated
using EBM
Evaluation of test parts Summarized in
Quarterly Report
Q3-
Y1
TBD TBD
M4 Development of
powder removal
strategies
Determination of methodologies
required for proper powder
removal
Successfully removing
powder for internal
cavities
Summarize results
in Quarterly
Report
Q3-
Y2
TBD TBD
M5 Fabrication of
instrumented low-NOx
fuel injectors
Fabricated low-NOx fuel
injectors using EBM and
containing cavities or channels
for sensors
Achieving fabrication
of re-engineered low-
NOx fuel injector
Summarize results
in Quarterly
Report
Q1-
Y3
TBD TBD
M6 Final testing of Low-
NOx fuel injectors
Results pertaining to embedded
sensors within low-NOx fuel
injectors enabled by EBM
Evaluation of test data
Summarized in
Quarterly Report
Q4-
Y3
TBD TBD
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DECISION POINT 1
Parameter: Development of design metrics for EBM-fabricated parts
Components: Tasks 1.1- 1.3
Bearing: The results from this component will determine the design constraints for the rest of the project
Planned Assessment: Q3-Y1
Successor: Task 1.3 Designs for sensor integration as an assembly process
DECISION POINT 2
Parameter: Development of powder removal strategies
Components: All previous tasks and Task 2.3
Bearing: Will demonstrate viability of using AM to fabricate low-NOx fuel injectors
Planned Assessment: Q4-Y1
Successor: Task 3.1-Testing and evaluation
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Thank You
W. M. Keck Center for 3D Innovation
University of Texas at El PasoEngineering Building Room 108
El Paso, Texas 79968
Tel: (915) 747 -7443; Fax: (915) 747- 5019
Email: [email protected]
keck.utep.edu
NASA MIRO Center for Space Exploration and Technology Research
University of Texas at El PasoEngineering Building Room M-305
El Paso, TX 79968-0521Tel: (915) 747-8252; Fax: (915) 747-5549
Email: [email protected]
research.utep.edu/csetr